Molded cup and manufacturing method thereof

ABSTRACT

A molded cup includes a first fabric layer, a cup core, and a second fabric layer. The first fabric layer and the second fabric layer are respectively provided on an outer surface and an inner surface of the cup core, and the cup core is filled with fluff. The cup core includes an upper layer, an intermediate layer, and a lower layer, the fluff is filled between the upper layer and the lower layer, and the upper layer and the lower layer of the cup core are manufactured by molding of a foam material. The molded cup enables breasts to breathe smoothly without being pressed, and can provide good support and protection effects and maintain comfort for the breasts.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of International Application No. PCT/CN2019/106814, filed on Sep. 19, 2019, which claims priorities from Chinese Patent Application No. 201910867008.0 filed on Sep. 12, 2019, all of which are hereby incorporated herein by reference.

TECHNICAL FIELD

The present invention relates to the technical field of bra design, and more particularly to a molded cup and a manufacturing method thereof.

BACKGROUND

As commonly used underwear for women, bras have functions of supporting, protecting and beautifying female breasts. An earlier origin of bras is a very tight corset that was popular among the European nobility in the Middle Ages. Since the corset is cumbersome, a bra using two handkerchiefs was invented and became an early form of modern bras.

An existing bra generally includes a breast part, a shoulder part, and a back part, and roughly includes: a hook and eye closure, a back strap, a shoulder strap, a ring, a slider, an over band, an upper cup, a lower cup, an apex, a front panel, a center gore, a side wing, a side seam, a back wing, a cradle, an under band, a wire, and a cup pad.

Female breasts are mostly adipose tissues with some ligaments and skin providing internal support. However, these supports are sometimes insufficient to support the breasts, and thus sagging breasts are caused. A bra is to provide external support for the breasts, bear gravity of the breasts, protect the breasts from sagging under gravity, and increase the comfort and mobility of the breasts. A good bra, in addition to being able to firmly support lower portions of the breasts and prevent the breasts from downward movement, can also relax the skin of the breasts and provides sufficient comfort for the breasts.

Bras on the market, however, either cannot closely fit the skin or are not breathable enough. Wearing an over-tightened bra often leads to indentations at the breast position. If the breasts are pressed for a long period of time, blocked circulation of vital energy and blood can be caused, and breast diseases easily occur, which affect breast health. However, if a bra being worn is too loose, it may be difficult to support the breasts, which may cause sagging breasts as time passes and the cups fail to play the original role. In addition, sizes of left and right cup cores of a bra are generally symmetrically arranged, but left and right breasts may be different in shape and size due to heartbeat and different working measurements of left and right hands in a human body, which affects comfort of wearing the bra.

SUMMARY

The present invention provides a molded cup and a manufacturing method thereof, which is filled with breathable fluff to increase cup volume and increase movement space of the cup, so that the breasts can breathe smoothly without being pressed and maintain comfortable.

According to the present invention, the molded cup includes a first fabric layer, a cup core, and a second fabric layer, in which the first fabric layer and the second fabric layer are respectively provided on an outer surface and an inner surface of the cup core, and the cup core is filled with fluff.

In the present invention, the cup core is filled with fluff having features of breathability, small density, and strong stretching force, and thus the cup can be increased in volume. Different people have different breast sizes, and thus it is also difficult to adapt to actual breast sizes for each person using only cup sizes. In particular, breasts of many people may not symmetrical in size due to reasons such as different workloads of left and right hands in a human body while the cups are generally symmetrically arranged, and thus the cups cannot match each breast.

According to the present invention, adaptability of the cup is improved after increasing the volume of the cup by filling fluff. For example, when a wearer has a large bust, the inside of the cup core is appropriately expanded outward from the breast, the fluff is subjected to pressure and adapts to the bust of the wearer by decreased thickness, so that cups in the same size can meet requirements of wearers having different cup sizes, especially wearers having left and right breasts different in shape and size, or wearers having different bust sizes.

The fluff may be cotton, down, or silk and other materials. The first fabric layer and the second fabric layer may be cotton or cloth, or the like.

The cup core includes an upper layer, an intermediate layer, and a lower layer. The fluff is filled between the upper layer and the lower layer, and the upper layer and the lower layer of the cup core are manufactured by molding of a foam material.

The foam material can facilitate filling fluff and avoid direct contact of the fluff with the first and second fabric layers; and has good support and shaping effects, thus avoiding deformation of the cups, and providing good support and protection for the breasts.

The cup core is provided with a plurality of holes at least in a central region thereof.

In the present invention, the plurality of holes can enhance stretchability of the cup core and intensify expandability of the cup core, so that the cup core fits the breasts better, and avoid displacement of the cups when the wearer is in motion. In addition, such configuration can also enhance the breathability of the cup core, as the holes may facilitate air flow from the cup core and achieve rapid air flow, reduced flow resistance, and increased breathable effects of the cup core, thereby enabling the breasts to smoothly breathe.

The plurality of holes enclose a diamond shape.

Particularly, two adjacent holes in a transverse direction and two adjacent holes in a longitudinal direction enclose a diamond shape.

In the present invention, two adjacent holes in a transverse direction and two adjacent holes in a longitudinal direction enclose a diamond shape, that is, center points of the four holes enclose a diamond shape, such that the cup has different stretching effects in longitudinal and transverse directions, which is suitable for the cup to have different stretching requirements at different positions, more suitable for the requirements of different groups of people, and more comfortable for the wearer.

Angles of an upper angle and a lower angle of the enclosed diamond are preferably smaller than angles of a left angle and a right angle of the diamond.

In the present invention, angles of an upper angle and a lower angle of the enclosed diamond are smaller than angles of a left angle and a right angle of the diamond, so that a range of transversely stretching the diamond is larger than a range of longitudinally stretching the diamond to adapt to people with more manual operations. When wearing a bra, breasts can be stretched in a right-left direction with a large stretching range, and the cups fit the breasts better, while the stretching range in the longitudinal direction is small to prevent the cups from moving up or down and failing to achieve a fixed effect.

However, the angles of the upper angle and the lower angle of the diamond can also be set to angles greater than the left angle and the right angle of the diamond as desired.

The angles of the upper angle and the lower angle of the enclosed diamond are 40 to 50 degrees, and the angles of the left angle and the right angle of the diamond are 130 to 140 degrees.

The angle of the upper angle and the lower angle of the enclosed diamond is preferably 45 degrees, and the angle of the left angle and the right angle of the diamond is preferably 135 degrees.

The diamond angle setting in the present invention can enable the holes to have more uniform stretching forces and stretching angles for the cups, and can make the wearer feel more comfortable.

The holes in the cup core are arranged throughout the entire cup core.

The fluff is filled in a central region between the upper layer and the lower layer, peripheral regions of the upper layer and the lower layer are attached to each other. The upper layer and the lower layer of the cup core are provided with a plurality of holes, regions provided with the holes extend to the peripheral regions of the upper layer and the lower layer, and the holes located in the peripheral regions of the upper layer and the lower layer are through-connecting.

The first fabric layer and the second fabric layer are bonded to the outer surface and the inner surface of the cup core by adhesive.

The cup core is manufactured by molding of a liquid foam material, and the fluff is filled between the liquid foam material.

The fluff is in non-contacting connection with the first fabric layer and the second fabric layer.

A manufacturing method suitable for the molded cup described above is further provided. The molded cup includes a first fabric layer, a cup core, and a second fabric layer. the manufacturing method includes the following steps:

S1. preparing a cup core using a die, and filling the cup core with fluff;

S2. covering the first fabric layer and the second fabric layer on an outer surface and an inner surface of the cup core respectively, and forming a semi-manufactured cup by low-temperature 3D fitting; and

S3. tailoring the semi-manufactured cup to obtain a bra cup.

Specifically, in step S1, the cup core includes an upper layer, an intermediate layer, and a lower layer. The fluff is filled in the intermediate layer of the cup core, and the upper layer and the lower layer of the cup core are formed by low-temperature molding of the foam material injected into the die.

The die includes a male die and a female die. In step S1, the manufacturing process of the cup core includes the steps of: injecting a first layer of foam material into the female die, then adding fluff on the first layer of foam material, continuing to inject a second layer of foam material over the fluff, folding the male die and the female die, and obtaining a cup core by low-temperature fitting. The first layer of foam material forms the upper layer of the cup core, and the second layer of foam material forms the lower layer of the cup core.

Step S1-2 is also included between step S1 and step S2: punching holes on the obtained cup core, and the holes are arranged throughout the cup core.

In step S2, the cup core is firstly bonded to the first fabric layer and second fabric layer by an adhesive, and then a semi-manufactured cup is obtained by low-temperature molding fitting.

According to the invention another manufacturing method suitable for the molded cup described above is further provided. The molded cup includes a first fabric layer and a second fabric layer. The manufacturing method includes the following steps:

S1. selecting a mold including a female die and a male die, and obtaining a corresponding cup shape by designing shapes of the female die and the male die;

S2. placing the first fabric layer on the female die, sequentially adding the first layer of foam material, the fluff and the second layer of foam material on the first fabric layer, then placing the second fabric layer on the second layer of foam material, folding the male die and the female die, and obtaining a semi-manufactured cup by low-temperature molding; and

S3. tailoring the semi-manufactured cup to obtain a bra cup.

The first fabric layer and the second fabric layer respectively cover the upper surface and the lower surface of the cup core to complete bonding at the same time.

Compared with the prior art, some beneficial effects of the present invention can be obtained.

According to the present invention, the cup is simple, quick and environment-friendly to manufacture. The cup is filled with breathable fluff to increase cup volume and increase movement space of the cup, which enables breasts to breathe smoothly without being pressed, and can provide good support and protection effects and maintain comfort for the breasts.

The manufacturing method of molded cup in the present invention is simple, convenient, and suitable for large-scale production. The manufactured molded cup has a good three-dimensional effect, and is not easy to deform and highly comfortable.

The manufacturing method of the present invention conforms more closely to low-carbon environmental protection concepts. The low-temperature fitting process according to the present invention can be set at 50° C., while a conventional molding process typically requires 195° C. Process material consumption according to the present invention can be controlled between 5% and 10%, while a conventional process typically require 40% consumption. The present invention thus can effectively save costs and conforms the low-carbon environmental protection concepts.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional structural view of a cup according to an embodiment.

FIG. 2 is a schematic flowchart showing manufacturing steps S1 to S4 of the cup according to an embodiment.

FIG. 3 is a schematic flowchart showing a manufacturing step S5 of the cup according to an embodiment.

FIG. 4 is a schematic structural view of a bra according to an embodiment of the present invention.

FIG. 5 is another cross-sectional structural view of a cup according to an embodiment.

FIG. 6 is another schematic flowchart showing manufacturing steps S1 to S2 of the cup according to an embodiment.

FIG. 7 is a schematic flowchart showing manufacturing steps S3 to S4 of the cup according to an embodiment.

FIG. 8 is another schematic flowchart showing a manufacturing step S5 of the cup according to an embodiment.

FIG. 9 is a schematic flowchart showing a manufacturing step S6 of the cup according to an embodiment.

FIG. 10 is a schematic structural diagram of a diamond form enclosed by holes according to an embodiment.

DETAILED DESCRIPTION

Drawings of the present invention are for illustrative purpose only and are not to be construed as limiting the invention. For better illustrating the following embodiments, some parts in the drawings may be omitted, enlarged, or reduced, and sizes of these parts do not represent that of actual products. For those skilled in the art, it will be understood that some known structures and descriptions thereof in the drawings may be omitted. It should be understood that embodiments of the present application are not limited to cups of a bra, but may also be applied to other clothes having cups. An inner side and an outer side in this application are defined for a body of a wearer. Thus, the inner side refers to a side close to the body of the wearer while the outer side refers to a side away from the body of the wearer.

As shown in FIGS. 1 and 4, in these embodiments, a molded cup includes a first fabric layer 510, a cup core 300, and a second fabric layer 520. The first fabric layer 510 and the second fabric layer 520 are respectively provided on an outer surface and an inner surface of the cup core 300. The cup core 300 is filled with fluff 320. The first fabric layer 510 and the second fabric layer 520 are respectively bonded to the outer surface and the inner surface of the cup core 300 by adhesive.

As shown in FIG. 2, according to an embodiment, the cup core 300 is manufactured by molding of a liquid foam material 310, and the fluff 320 is filled between the liquid foam material 310. The cup core 300 includes an upper layer 301, an intermediate layer, and a lower layer 302. The fluff 320 is filled between the upper layer 301 and the lower layer 302, and the upper layer 301 and the lower layer 302 of the cup core 300 are manufactured by molding of the foam material 310. The fluff 320 is in non-contacting connection with the first fabric layer 510 and the second fabric layer 520. The cup core 300 is manufactured by molding of the liquid foam material 310, and the fluff 320 is filled between the liquid foam material 310.

The fluff 320 is filled in a central region between the upper layer 301 and the lower layer 302, and peripheral regions of the upper layer 301 and the lower layer 302 are attached to each other.

As shown in FIGS. 2 and 3, the manufacturing method of the molded cup according to the present embodiment includes the following steps:

S1. selecting a foam mold including two parts of a male die 100 and a female die 200, in which a model of the foam mold corresponds to the shape of the cup core 300;

S2. placing the first fabric layer 510 into the female die 200;

S3. injecting an appropriate amount of foam material 310 over the first fabric layer 510, then placing a desired amount of fluff 320 over the foam material 310, and then continuing to inject an appropriate amount of liquid foam material 310 over the fluff 320;

S4. placing the second fabric layer 520 over the foam material 310 in step S3; and

S5. folding the male die 100 and the female die 200, taking out by low-temperature molding to obtain a semi-manufactured cup 530, and tailoring the semi-manufactured cup 530 to obtain a cup 500.

The cup core 300 in the present embodiment is filled with fluff 320 having features of breathability, small density, and strong stretching force, so that the cup 500 can be increased in volume.

The fluff 320 may be cotton, down, or silk and other materials; the first fabric layer 510 and the second fabric layer 520 may be cotton or cloth, or the like.

The foam material 310 is provided to facilitate filling fluff 320 and avoid direct contact of the fluff 320 with the first fabric layer 510 and the second fabric layer 520. In addition, the foam material 310 has good support and shaping effects, which can avoid deformation of the cups 500, and can also provide good support and protection for the breasts.

The following is a test on cup wearing effects of the present embodiment and a comparative example.

In this test, a cup in the comparative example differs from the cup 500 in the present embodiment in that no fluff 320 is added in the comparative example.

Test results are shown in Table 1 below:

TABLE 1 Embodiment Comparative Example Cup thickness Cup thickness Cup thickness Cup thickness (mm) before (mm) after (mm) before (mm) after fitting fitting fitting fitting Wearer 1 15 12 15 14 (bust: 34B) Wearer 2 15 8 15 12 (bust: 34C)

As can be seen from Table 1, the cup 500 in the present embodiment is mainly adapted to breast sizes by changing thickness of the cup 500 itself. While the cup in the comparative example presses the breasts in an opposite direction due to insufficient flexibility of the cup.

Therefore, according to the present embodiment, the adaptability of the cups 500 is improved after increasing volumes of the cups 500 by filling fluff 320. For example, when a wearer has a large bust, the inside of the cup core 300 is appropriately expanded outward from the breast, the fluff 320 is subjected to pressure and adapts to the bust of the wearer by decreased thickness, and achieves that cups 500 in the same size can meet requirements of wearers having different cup sizes, especially wearers having left and right breasts different in shape and size, or wearers having different bust sizes.

As shown in FIG. 5, in this embodiment, the cup core 300 of the molded cup is provided with a plurality of holes 400, and the plurality of holes 400 enclose a diamond shape. The holes 400 in the cup core 300 are provided throughout the entire cup core 300. The angle of the upper angle and the lower angle of the diamond enclosed by the plurality of holes 400 is 45 degrees, and the angle of the left angle and the right angle of the diamond is 135 degrees. Regions provided with the holes 400 in the cup core 300 extend to the peripheral regions of the upper layer 301 and the lower layer 302, and the holes 400 located in the peripheral regions of the upper layer 301 and the lower layer 302 are through-connecting.

In the present embodiment, the configuration of the plurality of holes 400 provided in the cup core 300 can enhance stretchability of the cup core 300 and intensify expandability of the cup core 300, so that the cup core fits the breasts better, and can avoid displacement of the cups 500 when the wearer is in motion. The breathability of the cup core 300 can also be enhanced with such configuration, as the holes 400 facilitate air flow from the cup core 300, which can achieve rapid air flow, reduced flow resistance, and increased breathable effects of the cup core 300, thereby enabling the breasts to smoothly breathe.

As shown in FIG. 10, two adjacent holes 400 in a transverse direction and two adjacent holes 400 in a longitudinal direction enclose a diamond shape among a plurality of holes 400.

An angle r of the upper angle and the lower angle of the enclosed diamond is 45 degrees, and an angle R of the left angle and the right angle of the diamond is 135 degrees.

As shown in FIGS. 6 to 9, in these embodiments, the manufacturing method of the molded cup includes the following steps:

S1. selecting a foam mold including two parts of a male die 100 and a female die 200, in which a model of the foam mold corresponds to the shape of the cup core 300;

S2. injecting the liquid foam material 310 into a corresponding shape of the female die 200 through a spraying head, then placing a desired amount of fluff 320 on the foam material 310, and continuing to inject an appropriate amount of liquid foam material 310 over the fluff 320;

S3. folding the male die 100 and the female die 200 and taking out a cup core 300 by low-temperature molding, in which the injected foam material 310 is shaped into the cup core 300 with a desired shape in a defined space of the foam mold;

S4. punching holes 400 on the cup core 300, the holes 400 passing through the cup core 300, the holes 400 forming a diamond shape on the surface of cup core 300, the angle of the upper angle and the lower angle of the diamond enclosed by the plurality of holes 400 is 45 degrees, and the angle of the left angle and the right angle of the diamond is 135 degrees;

S5. placing the first fabric layer 510 into the female die 200, then placing the cup core 300 obtained in step S4 on the first fabric layer 510, and then placing the second fabric layer 520 on the cup core 300; and

S6. folding the female die 200 and the male die 100 in step S5, obtaining a semi-manufactured cup 530 by molding, and tailoring the semi-manufactured cup 530 to obtain a cup 500.

In step S5, the cup core 300 is bonded to the first fabric layer 510 and the second fabric layer 520 respectively by an adhesive 330, the molding process can be under low temperature conditions that provide better protection for fabrics and protect color and surface of the cup 500. It should be noted that a manner to fit the cup core 300 with the first fabric layer 510 and the second fabric layer 520 is not limited to bonding using adhesive 330, but may also be in the form of spray coating, an adhesive film, and the like.

Obviously, the above embodiments of the present invention are merely examples for clear illustration of the technical solutions of the present invention, and are not intended to limit the implementation of the present invention. Any modification, equivalent substitution, improvement or the like within the spirit and principle of claims of the present invention should be included in the scope of the claims of the present invention. 

1. A molded cup, comprising: a first fabric layer; a cup core; and a second fabric layer, wherein the first fabric layer and the second fabric layer are respectively provided on an outer surface and an inner surface of the cup core, and the cup core is filled with fluff.
 2. The molded cup according to claim 1, wherein the cup core includes an upper layer, an intermediate layer, and a lower layer, the fluff is filled between the upper layer and the lower layer, and the upper layer and the lower layer of the cup core are manufactured by molding of a foam material.
 3. The molded cup according to claim 1, wherein the cup core is provided with a plurality of holes at least in a central region thereof, and two adjacent holes in a transverse direction and two adjacent holes in a longitudinal direction enclose a diamond shape.
 4. The molded cup according to claim 3, wherein angles of an upper angle and a lower angle of the diamond that is enclosed are smaller than angles of a left angle and a right angle of the diamond.
 5. The molded cup according to claim 2, wherein the fluff is filled in a central region between the upper layer and the lower layer, peripheral regions of the upper layer and the lower layer are attached to each other, and wherein the upper layer and the lower layer of the cup core are provided with a plurality of holes, regions provided with the holes extend to the peripheral regions of the upper layer and the lower layer, and the holes located in the peripheral regions of the upper layer and the lower layer are through-connecting.
 6. A manufacturing method of the molded cup according to claim 1, wherein the molded cup includes a first fabric layer, a cup core, and a second fabric layer, the manufacturing method comprising the following steps: S1. preparing a cup core using a die, and filling the cup core with fluff; S2. covering the first fabric layer and the second fabric layer on an outer surface and an inner surface of the cup core respectively, and forming a semi-manufactured cup by low-temperature 3D fitting; and S3. tailoring the semi-manufactured cup to obtain a bra cup.
 7. The manufacturing method of the molded cup according to claim 6, wherein in step S1, the cup core includes an upper layer, an intermediate layer, and a lower layer, the fluff is filled in the intermediate layer of the cup core, and the upper layer and the lower layer of the cup core are formed by low-temperature molding of a foam material injected into the die.
 8. The manufacturing method of the molded cup according to claim 7, wherein the die includes a male die and a female die, in step S1, a manufacturing process of the cup core includes: injecting a first layer of foam material into the female die, then adding fluff on the first layer of foam material, continuing to inject a second layer of foam material over the fluff, folding the male die and the female die, and obtaining a cup core by low-temperature fitting; in which the first layer of foam material forms the upper layer of the cup core, and the second layer of foam material forms the lower layer of the cup core.
 9. The manufacturing method of the molded cup according to claim 6, wherein step S1-2 is also included between step S1 and step S2, including the steps of: punching holes on the obtained cup core, and the holes being arranged throughout the cup core; and in step S2, firstly bonding the cup core to the first fabric layer and second fabric layer by an adhesive, and then obtaining a semi-manufactured cup by low-temperature molding fitting.
 10. A manufacturing method of the molded cup according to claim 1, wherein the molded cup comprises a first fabric layer and a second fabric layer, the manufacturing method comprising the following steps: S1. selecting a mold including a female die and a male die, and obtaining a corresponding cup shape by designing shapes of the female die and the male die; S2. placing the first fabric layer on the female die, sequentially adding the first layer of foam material, the fluff and the second layer of foam material on the first fabric layer, then placing the second fabric layer on the second layer of foam material, folding the male die and the female die, and obtaining a semi-manufactured cup by low-temperature molding; and S3. tailoring the semi-manufactured cup to obtain a bra cup. 